Lincoln-electric IDEALARC DC 1000 SVM123-A Uživatelský manuál

IDEALARC DC 1000SERVICE MANUALSales and Service through Subsidiaries and Distributors Worldwide22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.

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NOTES IDEALARC DC-1000F-62F-62Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

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F-64NOTES IDEALARC DC-1000F-64Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

G-1ELECTRICAL DIAGRAMSG-1IDEALARC DC-1000TABLE OF CONTENTS-ELECTRICAL DIAGRAMS SECTION-DIAGRAMS...

NOTES IDEALARC DC-1000Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master T

G-2ELECTRICAL DIAGRAMSIDEALARC DC1000Wiring Diagram (Codes 9919, 9920)9008 Ch'ge. Sht. No. 2-19-93G 3-19-93D 11-19-93C

G-3ELECTRICAL DIAGRAMSIDEALARC DC1000Operating SchematicTS 221423132TS 3R1S4-AS4-CCVICVICVSCVSS32CRL1L2L31CRSTARTSTOPR1CR2CRSECONDARYPRIMARYSHUNT21521

G-4ELECTRICAL DIAGRAMSIDEALARC DC1000Control PC Board (G1585) LayoutIDENTIFICATIONPART No.REQ'D.ITEM C3

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G-5ELECTRICAL DIAGRAMSIDEALARC DC1000Firing PC Board (G1486-5 and above) Layout1/4W 150 1/2W 5.1 1/4W 475

G-6ELECTRICAL DIAGRAMSIDEALARC DC1000Control PC Board (G1585) Schematic1.00KR22J110100V.047C6162R13375.0R142100V.047C2910KJ1815.0KR251N4004D35J281N400

G-7ELECTRICAL DIAGRAMSIDEALARC DC1000Firing PC Board (G1486-5 and above) SchematicG-7Return to Section TOC Return to Section TOC Return to Section TOC

G-8ELECTRICAL DIAGRAMSIDEALARC DC1000Output Snubber (M14312) Schematic600V.05C7600V.05C8160J320VTP7160J320VTP8NEG1POS1WELDERHAVING A COMMON CODE.19699

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A-9INSTALLATION IDEALARC DC-1000A-9CONNECTION FOR AIR/CARBON ARCCUTTING OPERATIONTHE OUTPUT TERMINALS ARE ENERGIZED ATALL TIMES WHEN THE IDEALARC DC

A-10NOTES IDEALARC DC-1000A-10Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCIDEALARC DC-1000B-1TABLE OF CONTENTS-OPERATION SECTION-OPERATION...

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ENGINEpowered equipment.1.a. Turn the engine off before trou-bl

B-4OPERATIONB-4• Three circuit solid state control system providesmaximum performance and circuit protection.• Low profile case provides maximum use o

B-5OPERATIONB-51. ON/OFF PUSH BUTTON: This push button turnsthe machine ON or OFF2. OUTPUT CONTROL POTENTIOMETER: Thiscontrol provides tapered, contin

B-6OPERATIONB-6OPERATING STEPSThe following procedures are for using the IDEALARCDC-1000 in the local control mode of operation. Forremote control of

B-7OPERATIONB-7GOOD ARC STRIKING GUIDELINES FOR THENA-3 WITH THE IDEALARC DC-1000 IN THE CVINNERSHIELD®, CV SUBMERGED ARC OR VV(CC) WELDING MODES.Foll

B-8OPERATIONB-8c. Set NA-3 Start Board current and voltageas close to the welding procedure currentand voltage as possible.NOTE: The Start Board curre

C-1ACCESSORIESC-1IDEALARC DC-1000TABLE OF CONTENTS-ACCESSORIES SECTION-ACCESSORIES...

C-2ACCESSORIESC-2OPTIONS/ACCESSORIES• Remote Control Box Assembly (K775)• LN-7• LN-8 }Semi-Automatic Wire Feeders• LN-9 • NA-3• NA-5 }Automatic Wire

C-3ACCESSORIESC-3d. Tape the #21 lead to work cable for easeof use.6. Connect the welding cables as shown in FigureC.1.NOTE: Welding cables must be of

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C-5ACCESSORIESC-5CONNECTING THE LN-9 WIRE FEEDERTO THE IDEALARC DC-10001. Set the ON/OFF PUSH BUTTON to the OFF pos-tion.2. Disconnect AC input power

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and

C-6ACCESSORIESC-6CONNECTING THE LN-7 WIRE FEEDER TOTHE IDEALARC DC-10001. Set the IDEALARC DC-1000 ON/OFF PUSHBUTTON to OFF.2. Disconnect main AC inpu

D-1MAINTENANCED-1IDEALARC DC - 1000TABLE OF CONTENTS-MAINTENANCE SECTION-MAINTENANCE...

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D-4NOTES IDEALARC DC-1000D-4Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCE-1THEORY OF OPERATIONE-1IDEALARC DC-1000TABLE OF CONTENTS-THEORY O

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E-4THEORY OF OPERATIONE-4PROTECTION DEVICES ANDCIRCUITS (CONTACTOR HOLD-IN)Two thermostats protect the DC-1000 from exces-sive operating temperatures.

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FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

E-6NOTES IDEALARC DC-1000E-6Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCIDEALARC DC-1000F-1TROUBLESHOOTING & REPAIRF-1TABLE OF CONTENTS

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SAFETYivPRÉCAUTIONS DE SÛRETÉPourvotre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parrai

F-10TROUBLESHOOTING & REPAIRF-10IDEALARC DC-1000Observe all Safety Guidelines detailed througout this manualIf for any reason you do not understan

F-11TROUBLESHOOTING & REPAIRF-11IDEALARC DC-1000Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understa

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F-14TROUBLESHOOTING & REPAIRF-14TEST PROCEDURE1. Disconnect main AC input power tothe machine.2. Remove the Top and Case Sides.3. Locate the Contr

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F-17TROUBLESHOOTING & REPAIRF-17TEST DESCRIPTION1. Disconnect main AC input power tothe machine.2. Inspect the Input Contactor,Reconnect Panel, an

F-18TROUBLESHOOTING & REPAIRF-18a. If one or more of the abovevoltage tests are incorrect,check for loose or faultywiring. If the wiring is good,t

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vIDEALARC DC - 1000MASTER TABLE OF CONTENTS FOR ALL SECTIONSPageSafety ...

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F-21TROUBLESHOOTING & REPAIRF-21TEST PROCEDURE FORNORMAL FIRINGBOARD OPERATION1. Disconnect main AC input power tothe machine.2. Remove screws, lo

F-22TROUBLESHOOTING & REPAIRF-2210. Rotate the output control poten-tiometer (R1). As the potentiometeris turned clockwise, the LEDsshould glow br

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F-26TROUBLESHOOTING & REPAIRF-26TEST PROCEDURE FORNORMAL CONTROL BOARDOPERATION1. Remove main supply power to theDC-1000.2. Remove screws, loosen

F-27TROUBLESHOOTING & REPAIRF-27POSSIBLE PROBLEMSPERTAINING TO THECONTROL BOARDIF LED 1 does not light, when thestart switch is ON.1. Check for 11

F-28TROUBLESHOOTING & REPAIRF-28IF LED 2 does not light when #2 and#4 are jumpered together.1. Check for the presence of open cir-cuit voltage at

F-29TROUBLESHOOTING & REPAIRF-29IF LED 3 does not light when theStart Button is depressed (but LED 1does light).The Fault Protection Relay (2CR) i

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCIDEALARC DC-1000A-1TABLE OF CONTENTS-INSTALLATION SECTION-INSTALLAT

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F-31TROUBLESHOOTING & REPAIRF-31TEST PROCEDURE1. Remove main supply power to theDC-1000.2. Remove all Molex plugs from thefiring board and control

F-32TROUBLESHOOTING & REPAIRF-323. Remove the red insulating paintfrom heat sink test points. SeeFigure 13.NOTE: DO NOT DISASSEMBLE THEHEAT SINKS.

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F-34TROUBLESHOOTING & REPAIRF-34IDEALARC DC-1000Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthor

F-35TROUBLESHOOTING & REPAIRF-351. Remove main supply power to theDC-1000.2. Remove all Molex plugs from theFiring Board and Control Board.See Fig

F-36TROUBLESHOOTING & REPAIRF-363. Remove the red insulating paintfrom heat sink test points. SeeFigure F.16.4. Perform test procedure as follows.

F-37TROUBLESHOOTING & REPAIRF-375. To test SCRs, construct the circuitoutlined in Figure F.17. Use one 6Vlantern battery. Resistor values arein oh

TROUBLESHOOTING & REPAIRF-38NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMCONSTANT CURRENT MODE - NO LOADIDEALARC DC-1000Volts/Div. . . . . . . . . . . . .

F-39TROUBLESHOOTING & REPAIRF-39NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMCONSTANT VOLTAGE INNERSHIELD - MAXIMUMOUTPUT SETTING - NO LOADIDEALARC DC-1000

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F-40TROUBLESHOOTING & REPAIRF-40NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMCONSTANT VOLTAGE INNERSHIELDMINIMUM OUTPUT SETTING - NO LOADIDEALARC DC-1000Vo

F-41TROUBLESHOOTING & REPAIRTYPICAL OUTPUT VOLTAGE WAVEFORM -MACHINELOADED CONSTANT VOLTAGE INNERSHIELD MODEIDEALARC DC-1000Volts/Div. . . . . . .

F-42TROUBLESHOOTING & REPAIRF-42TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINELOADED - 500 AMP OUTPUT TERMINALCONSTANT VOLTAGE INNERSHIELD MODEIDEALARC

F-43TROUBLESHOOTING & REPAIRF-43TYPICAL SCR GATE VOLTAGE WAVEFORMCONSTANT VOLTAGE INNERSHIELDMAXIMUM OUTPUT SETTING - NO LOADIDEALARC DC-1000SCOPE

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F-45TROUBLESHOOTING & REPAIRF-45IDEALARC DC-1000Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthor

F-46TROUBLESHOOTING & REPAIRF-46CLEANING PROCEDURE1. Remove main input supply power tothe DC-1000 and remove case topand sides.2. Locate the input

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